Hydroprocessing Catalyst Production with Low Carbon Support
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Solution Overview
Problem
In the GTL process, it is challenging to produce a hydroprocessing catalyst with high dispersibility of active metal and middle distillate selectivity due to abnormal heat generation caused by carbonaceous substance burning during calcination, leading to decreased catalyst performance.
Innovation Solution
A method involving a catalyst support with a carbonaceous substance content of 0.5% or less is used to support active metal components, preventing abnormal heat generation during calcination and ensuring high dispersibility and selectivity of the hydroprocessing catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a catalyst support with conventional carbonaceous substance content is used during calcination, then the active metal component can be supported effectively, but abnormal heat generation occurs due to carbonaceous substance burning, causing active metal aggregation and decreased catalyst performance
Solution Approach 1:
The catalyst support is prepared in advance with controlled carbonaceous substance content (0.5% or less) before the active metal component is supported. This preliminary control of carbon content prevents abnormal heat generation during subsequent calcination, thereby maintaining active metal dispersibility and preventing aggregation.
Solution Approach 2:
The carbonaceous substance content in the catalyst support is precisely controlled to 0.5% or less by mass, which fundamentally changes the thermal behavior during calcination. This parameter change eliminates the harmful combustion reaction that causes abnormal heat generation and active metal aggregation, while preserving the support's catalytic functionality.
2Reliability
If the carbonaceous substance content in the catalyst support is reduced to 0.5% or less, then abnormal heat generation is prevented during calcination, but the ease of manufacture of the catalyst support becomes more difficult
Solution Approach 1:
The carbonaceous substance content is precisely controlled to 0.5% or less by mass through optimized preparation conditions, including controlling drying temperature and time. This parameter control ensures reliable catalyst performance by preventing abnormal heat generation, while the standardized preparation protocol maintains manufacturing feasibility.
Solution Approach 2:
The conventional approach of mechanically removing carbonaceous substances through high-temperature combustion is replaced by controlling the initial carbon content to minimal levels. This substitution eliminates the need for aggressive calcination conditions that cause abnormal heat generation, while achieving the same or better catalyst performance stability.
3Productivity
If active metal aggregation occurs during catalyst production, then the catalyst can be manufactured more simply, but the middle distillate selectivity and yield are significantly decreased
Solution Approach 1:
The carbonaceous substance content is controlled to 0.5% or less before active metal support, which preliminarily prevents the conditions that lead to active metal aggregation during calcination. This preliminary control maintains high active metal dispersibility, ensuring high middle distillate selectivity and yield without requiring complex post-processing steps.
Solution Approach 2:
By changing the carbonaceous substance content parameter to 0.5% or less, the calcination process becomes more controlled and predictable, preventing active metal aggregation. This parameter change improves middle distillate yield while the standardized preparation method keeps the overall process complexity manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method stabilizes the production of hydroprocessing catalysts with high active metal dispersibility and middle distillate selectivity, enhancing the yield of branched aliphatic hydrocarbons and improving cold flow properties of fuel oils.
Implementation Method 1
abnormal heat generation caused by carbonaceous substance burning during calcination
Implementation Method 2
support an active metal component to obtain a catalyst precursor
Data Source
AI summary
The present invention provides a method for producing a hydroprocessing catalyst including a supporting step of allowing a catalyst support having a content of a carbonaceous substance containing carbon atoms of 0.5% by mass or less in terms of carbon atoms to support an active metal component containing at least one active metal element selected from metals belonging to Group 6, Group 8, Group 9 and Group 10 in the periodic table, to obtain a catalyst precursor, and a calcining step of calcining the catalyst precursor obtained in the supporting step to obtain the hydroprocessing catalyst.